Method and apparatus for assembling absorbent articles

ABSTRACT

The present disclosure relates to methods for assembling elastic laminates that may be used to make absorbent article components. Particular aspects of the present disclosure involve providing a first substrate and a second substrate, the first substrate and the second substrate, each having a width in a cross direction; providing an activated elastic material; elongating the activated elastic material; and ultrasonically bonding the first substrate together with the second substrate with the elongated activated elastic material positioned between the first substrate and the second substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/741,819, filed on Jan. 14, 2020, which is a continuation of U.S.patent application Ser. No. 15/674,625, filed on Aug. 11, 2017, whichclaims the benefit of U.S. Provisional Application No. 62/374,010, filedon Aug. 12, 2016; 62/406,025, filed on Oct. 10, 2016; and 62/419,515,filed on Nov. 9, 2016, the entireties of which are all incorporated byreference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods forassembling elastic laminates for making absorbent article components.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from an advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist bands, absorbentcore components, front and/or back ears, and fastening components. Oncethe desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles.

Some diaper components, such as leg elastics, barrier leg cuff elastics,stretch side panels, and waist elastics, are constructed from elasticlaminates. Such elastic laminates may be assembled in various waysdepending on the particular diaper design. For example, some elasticlaminates may be constructed from one or more nonwoven substrates bondedto an elastic film. In some configurations, the elastic film may bestretched and then bonded with the nonwoven substrates to form anelastic laminate.

Elastic laminates may be characterized by the force for a givenextension when used in a disposable absorbent article. The magnitude ofthe force required to extend the elastic laminate may vary between thefirst extension and subsequent extensions. In some configurations, theelastic laminate may include an elastic film that may comprise a baseelastic film, such as a styrenic-block copolymer, and surface layersalso known as skins. Such skins may help prevent interlayer adhesionwhen the elastic film is wound into a roll format for shipping andhandling. In some configurations, the skins may be a polyolefin, whichmay be 0.5-5 microns thick. However, the polyolefin skins on the surfaceof the elastic film may cause the higher initial extension forces for anelastic laminate. Some manufacturers of films may apply processes tohelp reduce the initial extension force for a given displacementrelative to subsequent extensions. For example, some manufactures offilms may apply a process, sometimes referred to as “activation,”wherein the films are extended or stretched to create a plurality ofcracks and tears in the skins at a microscopic scale. In turn, thesecracks and tears may help reduce the skin contribution to the extensionforces. In some configurations, activation operations are performedseparate to the assembly process, such as for example, activating thefilms offline wherein the films may be stored until needed forproduction. For example, activation operations may be accomplishedduring the manufacture of the films, separately from converting linesthat are dedicated to manufacturing elastic laminates the may be used indisposable absorbent articles. After manufacturing and activating thefilms, the films are delivered to the converting lines, such as in aform of continuous films wound onto a roll.

However, performing activation processes during film manufacture may berelatively inflexible and require extra processes and handling by thesupplier of such films, which in turn, may add costs. For example, whenimplemented as an offline process, the tooling may require tighttolerances that are relatively more difficult to achieve when applied torelatively wide films. In addition, films may be plastically deformed byactivation processes, such that the width of the activated film oncerelaxed is larger than the initial width. Such an increase in width mayresult in increased costs to the end user.

Consequently, it would be beneficial to provide methods and apparatusesfor assembling elastic laminates that are configured to performactivation processes that may be performed online during the articleassembly process.

SUMMARY OF THE INVENTION

In one form, a method for assembling elastic laminates comprises thesteps of: providing a first substrate and a second substrate, the firstsubstrate and the second substrate, each having a width in a crossdirection; providing an activated elastic material; elongating theactivated elastic material; and ultrasonically bonding the firstsubstrate together with the second substrate with the elongatedactivated elastic material positioned between the first substrate andthe second substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic side view of an apparatus for assembling anelastic laminate.

FIG. 1B is a top side view of the apparatus from FIG. 1A taken alongline 1B-1B.

FIG. 1C is a left side view of the apparatus from FIG. 1B taken alongline 1C-1C.

FIG. 1D is a detailed view of a spreader mechanism from FIG. 1C takenalong line 1E-1E.

FIG. 1E is a detailed view of radially protruding nubs on an outer rimof a disk.

FIG. 1F is a detailed view of an anvil from FIG. 1B taken along line1F-1F.

FIG. 1G is a detailed view of the anvil from FIG. 1F taken along line1G-1G.

FIG. 2A is a schematic side view of an apparatus operating to assemblean elastic laminate.

FIG. 2B is a left side view of the apparatus from FIG. 2A taken alongline 2B-2B.

FIG. 2C is a top side view of the apparatus from FIG. 2A taken alongline 2C-2C.

FIG. 2D is a detailed view of an elastic material advancing on aspreader mechanism from FIG. 2B taken along line 2D-2D.

FIG. 2E is a cross sectional view of the elastic laminate from FIG. 2Ataken along line 2E-2E.

FIG. 2F is a cross-sectional view of the elastic laminate from FIG. 2Ein a relaxed, contracted condition.

FIG. 2G is a left side view of the apparatus illustrating elasticmaterial being consolidated on the anvil.

FIG. 3A is a schematic side view of a second apparatus operating toassemble elastic laminates including a deflection member in the form ofan elongate member positioned between the first disk and the second diskof the spreader mechanism.

FIG. 3B is a left side view of the apparatus from FIG. 3A taken alongline 3B-3B.

FIG. 3C is a schematic side view of the second apparatus operating toassemble elastic laminates including a deflection member in the form ofa rotating disk positioned between the first disk and the second disk ofthe spreader mechanism.

FIG. 4 is a schematic side view of a third apparatus operating toassemble elastic laminates.

FIG. 4A is an isometric view of a ring rolling apparatus.

FIG. 5A is a partially cut away plan view of an absorbent article in theform of a taped diaper that may include one or more elastic laminatesmanipulated during manufacture according to the apparatuses and methodsdisclosed herein with the portion of the diaper that faces away from awearer oriented towards the viewer.

FIG. 5B is a plan view of the absorbent article of FIG. 5A that mayinclude one or more elastic laminates manipulated during manufactureaccording to the apparatuses and methods disclosed herein with theportion of the diaper that faces toward a wearer oriented towards theviewer.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Absorbentarticles can comprise sanitary napkins, tampons, panty liners,interlabial devices, wound dressings, wipes, disposable diapersincluding taped diapers and diaper pants, inserts for diapers with areusable outer cover, adult incontinent diapers, adult incontinent pads,and adult incontinent pants. The term “disposable” is used herein todescribe absorbent articles which generally are not intended to belaundered or otherwise restored or reused as an absorbent article (e.g.,they are intended to be discarded after a single use and may also beconfigured to be recycled, composted or otherwise disposed of in anenvironmentally compatible manner). “Diaper” is used herein to refer toan absorbent article generally worn by infants and incontinent personsabout the lower torso.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335,5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041,6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016,6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887A1; 2013/0211356 A1; and 2013/0306226 A1.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 50% greater than its initiallength and will substantially recover back to a length that is about 10%greater than the initial length or less upon release of the appliedforce.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

“Consolidation,” “consolidating,” and “consolidated” refers to amaterial undergoing a reduction in elongation from a first stretchedlength to a second stretched length that is less than the firststretched length and greater than zero.

“Relaxed state” defines a length of material when not stretched by anapplied force.

In the context of the present description, an elongation of 0% refers toa material in relaxed state having a relaxed length of L, and elongationof 150% represents 2.5x the relaxed length, L, of the material. Forexample, an elastic film having a relaxed length of 100 millimeterswould have a length of 250 millimeters at 150% elongation. And anelastic film having a relaxed length of 100 millimeters would have alength of 180 millimeters at 80% elongation.

The present disclosure relates to apparatuses and methods formanufacturing absorbent articles, and more particularly, apparatuses andmethods for assembling elastic laminates that may be used to makeabsorbent article components. Particular aspects of the presentdisclosure involve an anvil and a spreader mechanism adjacent the anvil.During the assembly process, a first substrate may be advanced in amachine direction onto the rotating anvil. The spreader mechanismoperates to activate an elastic material by stretching the elasticmaterial in the cross direction to a first elongation. The elasticmaterial is then consolidated to a second elongation in the crossdirection, wherein the second the elongation is less than the firstelongation. The consolidated elastic material is then bonded between afirst substrate and a second substrate on the anvil. The elasticmaterial and substrates may be bonded in various ways, such as forexample, with an ultrasonic bonding device. In some configurations, thefirst and second substrates may be nonwovens, and the elastic materialmay be an elastic film and/or an elastic laminate. As discussed in moredetail below, the elastic material may be activated and consolidatedbefore advancing to the anvil. In some configurations, the elasticmaterial may be activated before advancing to the anvil and may beconsolidated after advancing onto the anvil. The spreader mechanism andanvil configurations herein enable online activation processes that maybe conducted while assembling elastic laminates during an absorbentarticle assembly processes.

It is to be appreciated that aspects of the methods and apparatusesherein may be configured in various ways. To help provide additionalcontext to a subsequent discussion of the method configurations, thefollowing provides a description of apparatuses that may be configuredto operate in accordance with the methods disclosed herein.

FIGS. 1A-1C show schematic side views of an apparatus 100 configured toassemble elastic laminates. As shown in FIGS. 1A-1C, the apparatusincludes an anvil 102 having a cylindrically-shaped outercircumferential surface 104 and adapted to rotate in a first directionDir1 about a first axis of rotation 106. Although the first directionDir1 is depicted in FIG. 1A as clockwise, it is to be appreciated thatthe anvil 100 may be configured to rotate such that the first directionDir1 is counterclockwise. The anvil roll 100 may extend axially for alength between a first end 108 and a second end 110. As discussed inmore detail below, substrates and elastic materials may be combined onthe rotating anvil 102 to form an elastic laminate. It is to beappreciated that the substrates and elastic materials may be configuredin various ways. For example, the substrates may be configured asnonwovens, and the elastic materials may be configured as elastic filmsand/or elastic laminates.

As shown in FIG. 1B, the anvil 102, and more particularly, the outercircumferential surface 104 may also be fluidly connected with a vacuumpressure source 105. As such, vacuum air pressure may be used to helphold the substrates and elastic materials onto the outer circumferentialsurface 104 of the anvil 102 during operation. For example, as shown inFIG. 1G, the outer circumferential surface 104 of the anvil roll 102 mayinclude a plurality of apertures 114 fluidly connected with the vacuumpressure source 105. In turn, the apertures 114 may define a vacuum zone115 extending axially or in the cross direction CD for a width, Wvz. Forthe purposes of clarity, dashed lines 115 a, 115 b are shown in FIG. 1Gto represent example boundaries of the vacuum zone 115.

As mentioned above, elastic materials, such as elastic films, mayinclude a base elastic film and surface layers also known as skins.During activation, the films may be extended or stretched to create aplurality of cracks and tears in the skins at a microscopic scale,wherein such cracks and tears may help reduce the skin contribution tothe extension forces of the elastic film. With continued reference toFIGS. 1A-1C, the apparatus 100 may also include a spreader mechanism112. As discussed in more detail below, the spreader mechanism 112 mayoperate to activate the elastic material by stretching the elasticmaterial in a cross direction CD to a first elongation during theelastic laminate assembly process. The stretched elastic material isthen consolidated to a second elongation, wherein the second elongationis less than the first elongation. The elastic material is advanced fromthe spreader mechanism 112 onto a substrate on the rotating anvil 102.In some configurations, the spreader mechanism 112 may be configured toboth activate and consolidate the elastic material. In someconfigurations, the elastic material may be consolidated downstream ofthe spreader mechanism. It is to be appreciated that the apparatus 100may include more than one spreader mechanisms configured in variousways, such as disclosed for example in U.S. Patent Application Nos.62/374,010; 62/406,025; and 62/419,515.

As shown in FIGS. 1A-1E, the spreader mechanism 112 may be configuredwith canted disks. For example, the spreader mechanism 112 may include afirst disk 116 and a second disk 118, wherein the first disk 116 isdisplaced from the second disk 118 along the axis of rotation 106. Thefirst disk 116 is adapted to rotate about an axis of rotation 116 a andthe second disk 118 is adapted to rotate about an axis of rotation 118a, wherein the first and second disks 116, 118 rotate in a seconddirection Dir2 that is opposite the first direction Dir1. Although thesecond direction Dir2 is depicted in FIG. 1A as counterclockwise, it isto be appreciated that the disks 116, 118 may be configured to rotatesuch that the second direction Dir2 is clockwise. In addition, the firstdisk 116 includes an outer rim 116 b extending axially between an inneredge 116 c and an outer edge 116 d, and the second disk 118 includes anouter rim 118 b extending axially between an inner edge 118 c and anouter edge 118 d.

As shown in FIGS. 1A-1D, the first disk 116 and the second disk 118 arecanted relative to each other such that the outer rims 116 b, 118 b areseparated from each other by a distance D that increases from a minimumdistance Dmin at a first location 120 to a maximum distance Dmax at asecond location 122. As discussed below, an elastic material, such as anelastic film, may be advanced in a machine direction MD onto the outerrims 116 b, 118 b during operation. Because the first and second disks116, 118 are canted, rotation of the disks 116, 118 causes the rims 116b, 118 b to pull on edge regions of the elastic material and activatethe elastic material by stretching the elastic material in a crossdirection CD. The disks 116, 118 may also be configured to help gripopposing edge regions of the elastic material during operation. Forexample, with particular reference to FIGS. 1D and 1E, the first disk116 and the second disk 118 may each include a channel 124 extendingradially inward from the rims 116 b, 118 b. In turn, the channels 124may be fluidly connected with a vacuum pressure source 129. As such,vacuum air pressure may be used to help hold the elastic material ontothe rims 116 b, 118 b during operation. The disks 116, 118 may alsoinclude support members 126 extending across the channels 124 to thehelp prevent the elastic material from being drawn into the channels 124by the vacuum air pressure. As shown in FIGS. 1D and 1E, the disks 116,118 may also include nubs 128 that protrude radially outward from therims 116 b, 118 b. As such, the nubs 128 may also act to help preventthe edge regions of the elastic material from sliding along the rims 116b, 118 b while stretching the elastic material. It is to be appreciatedthat additional nubs 128 may be positioned inboard or outboard of thechannels 124. In addition, nubs 128 may also be positioned on thesupport members 126.

As mentioned above, stretched elastic materials and substrates arecombined on the anvil 102. The combined substrates and elastic materialsmay then be ultrasonically bonded together on the anvil 102 to formelastic laminates. As shown in FIGS. 1A and 1B, the apparatus 100 mayinclude one or more ultrasonic mechanisms 130 adjacent the anvil 102. Itis to be appreciated that the ultrasonic mechanism 130 may include ahorn 132 and may be configured to impart ultrasonic energy to thecombined substrates and elastic materials on the anvil 102. As shown inFIGS. 1F and 1G, the anvil roll 102 may include a plurality of patternelements 134 extending radially outward from the outer circumferentialsurface 104 of the anvil 102. As such, the ultrasonic mechanism mayapply energy to the horn 132 to create resonance of the horn atfrequencies and amplitudes so the horn 132 vibrates rapidly in adirection generally perpendicular to the substrates and elasticmaterials being advanced past the horn 132 on the rotating anvil 102.Vibration of the horn 132 generates heat to melt and bond the substratesand elastic material together in areas supported by the pattern elements134 on the anvil 102. It is to be appreciated that aspects of theultrasonic mechanisms may be configured in various ways, such asdisclosed for example in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238;6,036,796; 6,508,641; and 6,645,330. In some configurations, theultrasonic mechanism may be configured as a linear oscillating typesonotrode, such as for example, available from Herrmann Ultrasonic, Inc.In some configurations, the sonotrode may include a plurality ofsonotrodes nested together in the cross direction CD.

As previously mentioned, the apparatus 100 described above withreference to FIGS. 1A-1G may operate to assemble elastic laminatesconfigured in various ways. For example, FIGS. 2A-2D show variousschematic views of the apparatus 100 operating to assemble an elasticlaminate 200.

As shown in FIGS. 2A-2C, a first substrate 202 advances in a machinedirection MD onto the rotating anvil 102. More particularly, the firstsubstrate 202 includes a first surface 204 and an opposing secondsurface 206, and the first substrate 202 advances to wrap the firstsurface 204 onto the outer circumferential surface 104 of the rotatinganvil 102. During the assembly process, the spreader mechanism 112activates an elastic material 208 by stretching the elastic material 208to a first elongation in the cross direction CD. The stretched elasticmaterial 208 is then consolidated to a second elongation that is lessthan the first elongation. And the consolidated elastic material 208 ispositioned into contact with the second surface 206 of the firstsubstrate 202. As discussed in more detail below, the stretched elasticmaterial 208 may be consolidated before advancing to the anvil 102, andin some configurations, the elastic material 208 may be consolidatedafter advancing to the anvil 102. In turn, the elastic laminate 200 maybe formed by ultrasonically bonding the first substrate 202 and theelastic material 208 together with a second substrate 210 on the anvil102. More particularly, the second substrate 210 includes a firstsurface 212 and an opposing second surface 214, and the second substrate210 advances to position the first surface 212 in contact with theelastic material 208 and the second surface 206 of the first substrate202.

With continued reference to FIGS. 2A-2C, as the anvil 102 rotates, thefirst substrate 202, the elastic material 208, and the second substrate210 are advanced between the outer circumferential surface 104 of theanvil 102 and the ultrasonic horn 132. In turn, the ultrasonic horn 132bonds the first substrate 204, the elastic material 208, and the secondsubstrate 210 together to form the elastic laminate 200. As shown inFIGS. 2A and 2E, the elastic laminate 200 may then advance from theanvil 102 to additional absorbent article assembly processes. FIG. 2Falso shows the elastic laminate 200 in a relaxed state wherein thecentral region 208 c of the elastic material 208 is contracted in thecross direction CD. During the ultrasonic bonding process, it is to beappreciated that bonds imparted into the elastic laminate 200 from theultrasonic horn 132 may correspond with patterns and/or shapes definedby the plurality of pattern elements 134 extending radially outward fromthe outer circumferential surface 104 of the anvil 102. It is to beappreciated that the elastic laminate 200 may include various portionsof components bonded together in various ways and with differing oridentical bond patterns. For example, the elastic material 208 may bebonded together with the first and/or second substrates 202, 210, andthe first substrate 202 may be bonded directly to the second substrate210 in areas of the elastic laminate 200. It is to be appreciated thatthe apparatus 100 may be adapted to create various types of bondconfigurations, such as disclosed, for example, in U.S. Pat. No.6,572,595.

As previously mentioned, the spreader mechanism 112 activates theelastic material 208 by stretching the elastic material 208 to a firstelongation in the cross direction CD. With particular reference to FIGS.2A and 2D, the elastic material 208 includes a first edge 216 a and asecond edge 216 b separated from the first edge 216 a in the crossdirection CD. In addition, the elastic material 208 includes a firstedge region 208 a adjacent the first edge 216 a and a second edge region208 b adjacent the second edge 216 b. The first edge region 208 a isseparated from the second edge region 208 b in the cross direction CD bya central region 208 c. As shown in FIGS. 2A and 2B, the elasticmaterial 208 may define an initial width Wi in the cross direction CDbetween the first edge 216 a and the second edge 216 b upstream of thespreader mechanism 112. The elastic material 112 advances in a machinedirection MD onto the spreader mechanism 112 at or downstream of thefirst location 120. It is to be appreciated that elastic material 208may be at the initial width Wi in the cross direction CD while advancingonto the spreader mechanism 112. It is also to be appreciated that theelastic material 206 may be in a relaxed state upstream of the spreadermechanism 112.

As shown in FIGS. 2B and 2D, the first edge region 208 a of the elasticmaterial 208 advances onto the outer rim 116 b of the first disk 116 ofthe spreader mechanism 112, and the second edge region 208 b advancesonto the outer rim 118 b of the second disk 118. As previously discussedwith reference to FIG. 1D, the outer rims 116 b, 118 b of the first andsecond disks 116, 118 of the spreader mechanism 112 may include channels124 fluidly connected to a vacuum pressure source 129 and may includeradially protruding nubs 128. Thus, as shown in FIG. 2D, the first edgeregion 208 a of the elastic material 208 may be held in position on theouter rim 116 b with vacuum air pressure in the channels 124 and withthe radially protruding nubs 128. Similarly, the second edge region 208b of the elastic material 208 may be held in position on the outer rim118 b with vacuum air pressure in the channels 124 and with the radiallyprotruding nubs 128.

As discussed above with reference to FIG. 1D, the first disk 116 and thesecond disk 118 are canted. Thus, as the first disk 116 and the seconddisk 118 of the spreader mechanism 112 rotate, the elastic material 208is stretched in the cross direction CD while advancing from the firstlocation 120 or downstream of the first location 120 toward the secondlocation 122. Thus, as shown in the FIGS. 2A, 2B, and 2D, the spreadermechanism 112 may activate the elastic material 208 by stretching theelastic material 208 in the cross direction CD from the initial width Wi(and an initial elongation Ei) to a first width W1 (and a firstelongation E1) in the cross direction CD, wherein W1 is greater than Wiand wherein E1 is greater than Ei.

As the first disk 116 and the second disk 118 continue to rotate indirection Dir2 and advance the elastic material 208 past the secondlocation 122, the spreader mechanism 112 consolidates the elasticmaterial 208 to a second width W2 (and second elongation E2), wherein W2is less than W1 and wherein E2 is less than E1. It is to be appreciatedthat the elastic material 208 remains stretched at the second width W2(and second elongation E2). It is also to be appreciated that theelastic material 208 may be in a relaxed state at the initial width Wi(and initial elongation Ei), and as such, the second width W2 may begreater than the initial width Wi and the second elongation E2 may begreater than the initial elongation Ei.

It is to be appreciated that the apparatuses 100 herein may beconfigurated to operate with various extensions of elastic material. Insome configurations, the difference between the first elongation E1 andthe second elongation E2 may be about 25%. In some configurations,E1−E2=25%. In some configurations, when the spreader mechanism includescanted disks, the first and second edge regions 208 a, 208 b of theelastic material 208 may be held in position on the outer rims 116 b,118 b of the disks 116, 118. And as such, some portions of the first andsecond edge regions 208 a, 208 b may remain unstretched in the crossdirection CD as the first and second disks 116, 118 rotate. Thus, as thefirst disk 116 and the second disk 118 of the first spreader mechanism112 rotate, the central region 208 c of the elastic material 208 isstretched in the cross direction CD. In some configurations, the initialelongation Ei of the central region 208 c may be zero percent; the firstelongation E1 may be about 225%, and the second elongation may be about180%.

As shown in FIG. 2A-2D, the consolidated elastic material 208 advancesfrom the spreader mechanism 112 downstream of the second location 122 tothe anvil 102, and onto the second surface 206 of the first substrate202 on the anvil 102. And as the anvil 102 rotates, the second substrate210 advances onto anvil 102 to position the first surface 212 in contactwith elastic material 208 and the second surface 206 of the firstsubstrate 202 to form an elastic laminate 202 wherein the firstsubstrate 202, elastic material 208, and second substrate 210 are bondedtogether.

Although the spreader mechanism 112 can be configured to activate andconsolidate the elastic material 208 before advancing to the anvil 102,it is to be appreciated that in some configurations, the elasticmaterial 208 may be consolidated after advancing from the spreadermechanism 112 to the anvil 102. For example, as shown in FIG. 2G, theelastic material 208 advances in a machine direction MD onto thespreader mechanism 112 at or downstream of the first location 120. Andthe spreader mechanism 112 may activate the elastic material 208 bystretching the elastic material 208 in the cross direction CD from theinitial width Wi (and an initial elongation Ei) to a first width W1 (anda first elongation E1) in the cross direction CD, wherein W1 is greaterthan Wi and wherein E1 is greater than Ei. Once the elastic material 208advances to the second location 122 or before the elastic materialadvances to the second location 122 on the spreader mechanism 112, thestretched elastic material 208 having the first width W1 (and firstelongation E1) advances onto the anvil 102. As such, the elasticmaterial 208 may be removed from the spreader mechanism 112 at orupstream of the second location 122.

As previously mentioned, the outer circumferential surface 104 of theanvil 102 may be fluidly connected with the vacuum source 105, and assuch, vacuum air pressure may be applied to the first substrate 202 onthe anvil 102. In addition, when the first substrate 202 is configuredas a porous substrate, such as a nonwoven, vacuum air pressure may alsobe applied to the elastic material 208 on the anvil 102, and as such,may help maintain the stretched condition of the of the elastic material208 while on the anvil 102. As further discussed above with reference toFIG. 1G, the outer circumferential surface 104 of the anvil roll 102 mayinclude a plurality of apertures 114 fluidly connected with the vacuumpressure source 105. In turn, the vacuum zone 115 defined by theapertures 114 extends axially or in the cross direction CD for a width,Wvz. As such, the vacuum pressure exerted on the elastic material 208while on the anvil 102 may maintain the width of the elastic material208 at a width that is equal to or about equal to the width Wvz of thevacuum zone 115. In some configurations, the width Wvz of the vacuumzone 115 may be less than the first width W1 of the elastic material 208advancing from the spreader mechanism 112. Thus, as shown in FIG. 2G,the elastic material 208 advancing to the anvil roll 102 from thespreader mechanism 112 may be consolidated to a second width W2 (andsecond elongation E2) as defined by the width Wvz of the vacuum zone115, wherein W2 and Wvz are both less than W1 and wherein E2 is lessthan E1. It is also to be appreciated that the elastic material 208 maybe consolidated to the second width W2 (and second elongation E2) whileadvancing from the spreader mechanism 112 to the anvil 102. It is alsoto be appreciated that the elastic material 112 may be partiallyconsolidated while on the spreader mechanism 112 and while on the anvil102.

It is also to be appreciated that aspects of the spreader mechanisms 112may be configured in various ways. For example, the cross direction CDpositions of the disks 116, 118 of the spreader mechanism 112 may beadjustable relative to each other. In addition, canting angles of thedisks 116, 118 of the spreader mechanism 112 may be adjustable. Thecanting angle of the first disk 116 may be defined as an angular offsetbetween the axis of rotation 116 a of the first disk 116 and the axis ofrotation 106 of the anvil 102, and the canting angle of the second disk118 may be defined as an angular offset between the axis of rotation 118a of the second disk 118 and the axis of rotation 106 of the anvil 102.In some configurations, radial clearances between the outercircumferential surface 104 of the anvil 102 and the outer rims 116 b,118 b of the first and second disks 116, 118 of the spreader mechanisms112 may be adjustable, wherein the positions of the disks 116, 118 maybe configured to be independently or collectively adjustable. In someconfigurations, the radial clearance between the outer circumferentialsurface 104 of the anvil 102 and the outer rims 116 b, 118 b may be zeroor greater than zero.

It is to be appreciated that various drives may be used to control therotation of the disks 116, 118 of the spreader mechanism 112. Forexample, the disks 116, 118 of the spreader mechanism 112 may be drivenby one or more motors, such as a servo motor. In some configurations,motors may be directly connected with the disks 116, 118, and in someconfigurations, motors may be indirectly connected with the disks 116,118, such as through belts, pulleys, and/or gears. The disks 116, 118may be driven as a pair through the use of a common driveshaft with acoupling between the disks. In some configurations, a common jackshaftmay be used to drive both disks 116, 118 together with a single motor.In some configurations, drives of the anvil 102 and spreader mechanism112 may be operatively connected, and may be configured with a singlemotor. In some configurations, the disks 116, 118 of the spreadermechanism 112 may be driven only by the advancement of the elasticmaterial 208. In some configurations, the disks 116, 118 of the spreadermechanism 112 may be driven by rotation of the anvil 102 or an infeedidler. Other drives may include surface driving through a jackshaft witha friction material in operative contact with disks 116, 118.

It is to be appreciated that the spreader mechanism 112 may beconfigured to activate the elastic material 208 in various ways. Forexample, as shown in FIGS. 3A and 3B, the spreader mechanism 112 mayinclude a deflection member 136 positioned between the first disk 116and the second disk 118. During operation, the central region 208 c theelastic material 208 may advance along the deflection member 136 as thefirst disk 116 and the second disk 118 rotate. In turn, the deflectionmember 136 deflects the central region 208 c of the elastic materialinto the space between the first disk 116 and the second disk 118. Thedeflection imparted by the deflection member 136 onto the elasticmaterial 208 causes the elastic material 208 to stretch. As such, thestretching caused by the deflection member 136 may be configured toimpart stretch that is in addition to the stretch caused by the cantedrelationship of the first disk 116 and the second disk 118.

It is to be appreciated that the deflection member 136 may be configuredin various ways. For example, the deflection member 136 is illustratedin FIGS. 3A and 3B as an elongate member 136 a extending in the machinedirection MD between the first disk 116 and the second disk 118. Inanother example, such as shown in FIG. 3C, the member may be configuredas a rotating disk 136 b positioned between the first disk 116 and thesecond disk 118. In some configurations, the deflection member 136 maybe configured with a pneumatic device so as to discharge air onto theelastic material 208. In some configurations, the elastic material 208may be supported on a layer of compressed air from the deflection member136. In some configurations, the position and/or geometry of thedeflection member 136 may be adjustable, which in turn, may allow forregulation of the first width W1 (and first elongation E1). It is to beappreciated that the deflection member 136 may be arranged and/orconfigured with respect to the disks 116, 118 such that the first disk116 and the second disk 118 may be parallel with respect to each other,as opposed to being canted. It is also to be appreciated that thedeflection member 136 may be arranged and/or configured with respect tothe disks 116, 118 such that the elastic material 208 may beconsolidated before or after advancing to the second location 122. It isalso to be appreciated that the deflection member 136 may be configuredwith curved and/or straight regions, and may be configured to deflectthe elastic material 208 outward from between the disks 116, 118. Asdiscussed above, once activated, the stretched elastic material 208 maybe then be consolidated on the spreader mechanism 112 shown in FIGS. 3Aand 3B and/or may be consolidated on the anvil 102.

As shown in FIG. 4 , the spreader mechanism 112 may include a ringrolling apparatus 138, such as disclosed for example in U.S. Pat. Nos.4,116,892; 4,834,741; 5,143,679; 5,156,793; 5,167,897; 5,422,172; and5,518,801; and 9,687,580. In some configurations, the ring rollingapparatus 138 may include two profile rollers 140, such as shown forexample in FIG. 4A. It is to be appreciated that the rollers 140 such asshown in FIG. 4A may also be configured to be duplicate to each other.Each roller 140 may include at least two disk packets having a pluralityof intermeshing disks that are situated on an axis. Referring back toFIG. 4 , the elastic material 208 may advance through a nip between thetwo profile rollers 140, and in turn, the ring rolling apparatus 138activates the elastic material 208 by stretching the elastic material208 in the cross direction CD from the initial width Wi (and an initialelongation Ei) to a first width W1 (and a first elongation E1) in thecross direction CD, wherein W1 is greater than Wi and wherein E1 isgreater than Ei. The activated elastic material 208 may then advance tothe first disk 116 and the second disk 118 at or downstream of thesecond location 122. As the first and second disks 116, 118 rotate andadvance the elastic material 208 downstream of the second location 122,the elastic material 208 is consolidated to a second width W2 (andsecond elongation E2), wherein W2 is less than W1 and wherein E2 is lessthan E1. The consolidated elastic material 208 then advances from thefirst disk 116 and the second disk 118 and onto the anvil 102. It isalso to be appreciated that the apparatus 100 shown in FIG. 4 may bemodified to eliminate the first disk 116 and the second disk 118, and assuch, the activated elastic material 208 may advance directly to theanvil 102 from the ring rolling apparatus 138. As such, the elasticmaterial 208 may be consolidated to the second width W2 (and secondelongation E2) while advancing from the ring rolling apparatus 138 tothe anvil 102 and/or may be consolidated while on the anvil 102 asdiscussed above.

It is to be appreciated that the apparatus 100 herein may be configuredto activate the elastic material 208, in various ways. For example, theapparatus 100 may be configurated to create zones in components of theelastic material 208 that have different stretch properties, tactiledifferences, and/or aesthetic differences, such as disclosed in U.S.Pat. No. 8,118,801 and U.S. Patent Publication No. US20120143165A1. Insome configurations, the apparatus 100 may be configured to activate theelastic material 208 in the machine direction MD and/or the crossdirection CD, such as disclosed in U.S. Pat. Nos. 7,824,594; 7,896,641;and 8,062,572.

It is to be appreciated that aspects of the apparatus 100 herein may beconfigured to assemble elastic laminates from various types of materialand/or components. For example, it is to be appreciated that the firstsubstrate 202 and/or the second substrate 210 discussed above may beconfigured as the same or different types of materials. For example, thesubstrates 202, 210 may be configured as single layer or multi-layernonwovens. As previously mentioned the elastic material 208 may beconfigured in various ways and from various materials. For example, theelastic material may be formed by any suitable method in the art, forexample, by extruding molten thermoplastic and/or elastomeric polymersor polymer blends through a slit die and subsequently cooling theextruded sheet. Other non-limiting examples for making film formsinclude casting, blowing, solution casting, calendaring, and formationfrom aqueous or, non-aqueous cast dispersions. The elastomer compositionmay be made into a film having a basis weight of from about 5 to about150 g/m². The elastic material can also be an apertured film made ofelastomeric material to provide breathability. In some configurations,the elastic material include a nonwoven web of synthetic fibers. The webcan be made of fibers from elastomers or can be mixture of elastomericfibers with plastic fibers. The elastic material may also be configuredas laminates including elastic material connected with and/or interposedbetween an outer layer and an inner layer. The elastic material mayinclude one or more elastic elements such as strands, ribbons, orpanels. Suitable elastomeric compositions for making elastic materialscomprise thermoplastic elastomers selected from the group consisting ofstyrenic block copolymers, poly-esters, polyurethanes, polyether amides,polyolefin elastomers, and combinations thereof.

Although the apparatus 100 may be configured to operate online as partof an absorbent article assembly process, it is to be appreciated thataspects of the apparatus 100 herein may be configured in various waysand may operate to assemble elastic laminates 200 from various types ofmaterial and/or components. For example, it is to be appreciated that insome configurations, the elastic laminate assembly operations may beperformed separate to a final assembly process, such as for example,assembling the elastic laminates offline wherein the elastic laminatesmay be stored until needed for production. For example, elastic laminateassembly operations may be accomplished on discrete assembly lines,separately from converting lines that may be dedicated to manufacturingdisposable absorbent articles. After assemblage on the discrete lines,the elastic laminates may be delivered to the absorbent articleconverting lines, such as in a form of rolls of continuous elasticlaminates. It is to be appreciated that such rolls of continuous elasticlaminates may be planetary wound or traversely wound. It is alsoappreciated that the elastic laminate assembly process may be doneonline during the article assembly process.

It is also to be appreciated that the features illustrated or describedin connection with one non-limiting configuration may be combined withthe features of other non-limiting configurations. Such modificationsand variations are intended to be included within the scope of thepresent disclosure.

As mentioned above, apparatuses and methods of the present disclosuremay be utilized to assembly various forms of elastic laminates used inthe manufacture of absorbent articles. Such elastic laminates may beutilized in absorbent article components such as, for example:backsheets, topsheets, absorbent cores, front and/or back ears, fastenercomponents, and various types of elastic webs and components such as legelastics, barrier leg cuff elastics, and waist elastics. For thepurposes of a specific illustration, FIGS. 5A and 5B show an example ofa disposable absorbent article 250 in the form of a diaper 252 that maybe constructed from such elastic laminates manipulated duringmanufacture according to the apparatuses and methods disclosed herein.In particular, FIG. 5A is a partially cut away plan view of an absorbentarticle in the form of a taped diaper that may include one or moreelastic laminates assembled during manufacture according to theapparatuses and methods disclosed herein with the portion of the diaperthat faces away from a wearer oriented towards the viewer. FIG. 5B is aplan view of the absorbent article of FIG. 5A that may include one ormore elastic laminates assembled during manufacture according to theapparatuses and methods disclosed herein with the portion of the diaperthat faces toward a wearer oriented towards the viewer.

As shown in FIGS. 5A and 5B, the diaper 252 includes a chassis 254having a first ear 256, a second ear 258, a third ear 260, and a fourthear 262. To provide a frame of reference for the present discussion, thechassis is shown with a longitudinal axis 264 and a lateral axis 266.The chassis 254 is shown as having a first waist region 268, a secondwaist region 270, and a crotch region 272 disposed intermediate thefirst and second waist regions. The periphery of the diaper is definedby a pair of longitudinally extending side edges 274, 276; a first outeredge 278 extending laterally adjacent the first waist region 268; and asecond outer edge 280 extending laterally adjacent the second waistregion 270. As shown in FIGS. 5A and 5B, the chassis 254 includes aninner, body-facing surface 282, and an outer, garment-facing surface284. A portion of the chassis structure is cut-away in FIG. 5A to moreclearly show the construction of and various features that may beincluded in the diaper. As shown in FIGS. 5A and 5B, the chassis 254 ofthe diaper 252 may include a topsheet 288 defining the inner,body-facing surface 282, and a backsheet 290 defining the outer,garment-facing surface 284. An absorbent core 292 may be disposedbetween a portion of the topsheet 288 and the backsheet 290. Asdiscussed in more detail below, any one or more of the regions may bestretchable and may include an elastomeric material or laminate asdescribed herein. As such, the diaper 252 may be configured to adapt toa specific wearer's anatomy upon application and to maintaincoordination with the wearer's anatomy during wear.

The absorbent article 250 may also include an elastic waist feature 202shown in FIG. 5B in the form of a waist band and may provide improvedfit and waste containment. The elastic waist feature 202 may beconfigured to elastically expand and contract to dynamically fit thewearer's waist. The elastic waist feature 202 can be incorporated intothe diaper and may extend at least longitudinally outwardly from theabsorbent core 292 and generally form at least a portion of the firstand/or second outer edges 278, 280 of the diaper 252. In addition, theelastic waist feature may extend laterally to include the ears. Whilethe elastic waist feature 202 or any constituent elements thereof maycomprise one or more separate elements affixed to the diaper, theelastic waist feature may be constructed as an extension of otherelements of the diaper, such as the backsheet 290, the topsheet 288, orboth the backsheet and the topsheet. In addition, the elastic waistfeature 202 may be disposed on the outer, garment-facing surface 284 ofthe chassis 254; the inner, body-facing surface 282; or between theinner and outer facing surfaces. The elastic waist feature 202 may beconstructed in a number of different configurations including thosedescribed in U.S. Patent Publication Nos. 2007/0142806 A1; 2007/0142798A1; and 2007/0287983 A1, all of which are hereby incorporated byreference herein.

As shown in FIGS. 5A and 5B, the diaper 252 may include leg cuffs 296that may provide improved containment of liquids and other bodyexudates. In particular, elastic gasketing leg cuffs can provide asealing effect around the wearer's thighs to prevent leakage. It is tobe appreciated that when the diaper is worn, the leg cuffs may be placedin contact with the wearer's thighs, and the extent of that contact andcontact pressure may be determined in part by the orientation of diaperon the body of the wearer. The leg cuffs 296 may be disposed in variousways on the diaper 202.

The diaper 252 may be provided in the form of a pant-type diaper or mayalternatively be provided with a re-closable fastening system, which mayinclude fastener elements in various locations to help secure the diaperin position on the wearer. For example, fastener elements 298 may belocated on the ears and may be adapted to releasably connect with one ormore corresponding fastening elements located in the first or secondwaist regions. For example, as shown in FIG. 5A, the diaper 252 mayinclude a connection zone 282, sometimes referred to as a landing zone,in the first waist region 268. It is to be appreciated that varioustypes of fastening elements may be used with the diaper.

EXAMPLES

A. A method for assembling elastic laminates, the method comprising thesteps of: providing a first substrate and a second substrate, the firstsubstrate and the second substrate each comprising a first surface andan opposing second surface, and defining a width in a cross direction;wrapping the first surface of the first substrate onto an outercircumferential surface of an anvil; advancing an elastic film to aspreader mechanism, the elastic film comprising a first edge and asecond edge separated from the first edge in the cross direction by acentral region; stretching the elastic film at the spreader mechanism inthe cross direction to a first elongation; advancing the elastic filmfrom the spreader mechanism to the anvil; consolidating the elastic filmto a second elongation in the cross direction, wherein the second theelongation is less than the first elongation; positioning theconsolidated elastic film in contact with the second surface of thefirst substrate on the anvil; advancing the second substrate to positionthe first surface of the second substrate in contact with theconsolidated elastic film and the second surface of the first substrateon the anvil; and ultrasonically bonding the first substrate togetherwith the second substrate with the elastic film positioned between thefirst substrate and the second substrate.

B. The method according to paragraph A, wherein the spreader mechanismcomprises a first disk and a second disk canted relative each other,each disk comprising an outer rim, wherein as the first and second disksrotate, the outer rims are separated from each other by a distance thatincreases from a minimum distance at a first location to a maximumdistance at a second location.

C. The method according to paragraph B, further comprising the steps of:advancing the elastic film onto the first disk and the second disk at ordownstream of the first location; stretching the elastic film to thefirst elongation in the cross direction by rotating the first disk andthe second disk of the spreader mechanism.

D. The method according to paragraph C, wherein the step ofconsolidation further comprises: advancing the elastic film on therotating first disk and second disk downstream of the second location.

E. The method according to paragraph D, further comprising the step ofremoving the elastic film from the first disk and the second diskdownstream of the second location and advancing the elastic film fromthe spreader mechanism to the anvil.

F. The method according to paragraph C, wherein the step of stretchingthe elastic film further comprises advancing the central region of theelastic film along a deflection member positioned between the first diskand the second disk.

G. The method according to paragraph F, wherein the deflection membercomprises a rotating disk.

H. The method according to paragraph A, wherein the spreader mechanismcomprises a ring rolling apparatus.

I. The method according to paragraph H, further comprising the step ofadvancing the elastic film from the ring rolling apparatus to a firstdisk and a second disk, wherein the first disk and the second disk arecanted relative each other, each disk comprising an outer rim, whereinas the first and second disks rotate, the outer rims are separated fromeach other by a distance that increases from a minimum distance at afirst location to a maximum distance at a second location.

J. The method according to paragraph I, wherein the step ofconsolidating further comprises: advancing the elastic film on therotating first disk and second disk downstream of the second location.

K. A method for assembling elastic laminates, the method comprising thesteps of: providing a first substrate and a second substrate, the firstsubstrate and the second substrate each comprising a first surface andan opposing second surface, and defining a width in a cross direction;wrapping the first surface of the first substrate onto an outercircumferential surface of an anvil; advancing an elastic film to aspreader mechanism, the elastic film comprising a first edge and asecond edge separated from the first edge in the cross direction by acentral region; activating the elastic film by stretching the elasticfilm at the spreader mechanism in the cross direction to a firstelongation; advancing the elastic film from the spreader mechanism tothe anvil; positioning the elastic film in contact with the secondsurface of the first substrate on the anvil; consolidating the elasticfilm on the anvil to a second elongation in the cross direction, whereinthe second the elongation is less than the first elongation; advancingthe second substrate to position the first surface of the secondsubstrate in contact with the elastic film and the second surface of thefirst substrate on the anvil; and bonding the first substrate togetherwith the second substrate with the elastic film in the second elongationpositioned between the first substrate and the second substrate.

L. The method according to paragraph K, wherein the spreader mechanismcomprises a first disk and a second disk canted relative each other,each disk comprising an outer rim, wherein as the first and second disksrotate, the outer rims are separated from each other by a distance thatincreases from a minimum distance at a first location to a maximumdistance at a second location.

M. The method according to paragraph L, further comprising the steps of:advancing the elastic film onto the first disk and the second disk at ordownstream of the first location; stretching the elastic film to thefirst elongation in the cross direction by rotating the first disk andthe second disk.

N. The method according to paragraph M, further comprising the step ofremoving the elastic film from the first disk and the second disk at,upstream, or downstream of the second location and advancing the elasticfilm from the first disk and the second disk to the anvil.

O. The method according to paragraph L, wherein the step of stretchingthe elastic film further comprises advancing the central region of theelastic film along a deflection member positioned between the first diskand the second disk.

P. The method according to paragraph O, wherein the deflection membercomprises a rotating disk.

Q. The method according to paragraph K, wherein the spreader mechanismcomprises a ring rolling device.

R. The method according to any one of paragraphs K-Q, wherein the anvilcomprises a vacuum zone comprising a width W extending in the crossdirection, wherein the width W is less than the first elongation; andwherein the step of consolidating further comprises advancing thestretched elastic film from the spreader mechanism onto the vacuum zone.

S. The method according to any one of paragraphs K-Q, wherein the stepof bonding further comprises advancing the first substrate, the secondsubstrate, and the elastic film between the outer circumferentialsurface of the anvil and an ultrasonic horn.

T. An apparatus for making elastic laminates, the apparatus comprising:an anvil comprising an outer circumferential surface and adapted torotate in a first direction about an axis of rotation, a plurality ofpattern elements extending radially outward from the outercircumferential surface, the anvil extending axially from a first end toa second end in a cross direction; an ultrasonic horn adjacent the outercircumferential surface; a spreader mechanism upstream of the anvil in amachine direction and adapted to stretch an advancing elastic film inthe cross direction to a first elongation; and a means for consolidatingthe stretched elastic film to a second elongation in the crossdirection, wherein the second elongation is less than the firstelongation.

This application claims the benefit of U.S. Provisional Application Nos.62/374,010, filed on Aug. 12, 2016; 62/406,025, filed on Oct. 10, 2016;and 62/419,515, filed on Nov. 9, 2016, the entireties of which are allincorporated by reference herein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for assembling elastic laminates, themethod comprising steps of: providing a first substrate and a secondsubstrate, the first substrate and the second substrate, each having awidth in a cross direction and each having a first surface and anopposing second surface; providing an activated elastic material;elongating the activated elastic material using a spreader mechanism;and ultrasonically bonding the first substrate together with the secondsubstrate with the elongated activated elastic material positionedbetween the first substrate and the second substrate.
 2. The method ofclaim 1 wherein the step of elongating the activated elastic materialcomprises elongating the activated elastic material in a cross machinedirection.
 3. The method of claim 1 wherein the first substrate is anonwoven.
 4. The method of claim 3 wherein the seconds substrate is anonwoven.
 5. The method of claim 1 wherein the activated elasticmaterial is an elastic film.
 6. The method of claim 1 wherein theactivated elastic material comprises a skin having a plurality of tears.7. The method of claim 6 wherein the plurality of tears are formed by aring rolling apparatus.
 8. The method of claim 6 wherein the pluralityof tears extend in a machine direction.
 9. The method of claim 1 whereinthe step of ultrasonically bonding the first substrate, second substrateand elongated activated elastic material comprises disposing the firstsubstrate, second substrate, and elongated activated elastic materialproximate to a plurality of pattern elements and applying ultrasonicenergy to bond the substrates and activated elastic material to formdiscrete bonds in areas corresponding to the pattern elements.
 10. Themethod of claim 1 wherein the elongated activated elastic materialcomprises an elongation that is greater than an elongation of the firstand second substrates, such that the first and second substrates formgathers when the assembled elastic laminate is in a relaxed condition.11. The method of claim 1 wherein the activated elastic material iscapable of stretching to a first elongation and wherein the step ofelongating the activated elastic material comprises elongating theactivated elastic material to a second elongation, wherein the secondelongation is less than the first elongation.
 12. The method of claim 11wherein the second elongation is about 25% less than the firstelongation.
 13. The method of claim 1 wherein the spreader mechanismcomprises the first disk and the second disk are canted relative eachother, wherein the first and second disks rotate.
 14. The method ofclaim 1 further comprising the steps of: wrapping the first surface ofthe first substrate onto an outer circumferential surface of an anvil;positioning the activated elastic material in contact with the secondsurface of the first substrate on the anvil; advancing the secondsubstrate to position the first surface of the second substrate incontact with the activated elastic material and the second surface ofthe first substrate on the anvil.
 15. The method of claim 1 furthercomprising the step of using the spreader mechanism to hold one or moreedge regions of the elastic material in position, such that the one ormore edge regions remain unstretched.
 16. The method of claim 1 furthercomprising the step of applying vacuum air pressure to the elasticmaterial.
 17. The method of claim 16 wherein an anvil comprises anvacuum source, and the step of applying vacuum air pressure comprisesapplying vacuum air pressure to the elastic material on the anvil.
 18. Amethod for assembling elastic laminates, the method comprising steps of:providing a first substrate and a second substrate, the first substrateand the second substrate, each having a width in a cross direction andeach having a first surface and an opposing second surface; providing anactivated elastic film; wrapping the first surface of the firstsubstrate onto an outer circumferential surface of an anvil, wherein theanvil comprises a vacuum source; positioning the activated elastic filmin contact with the second surface of the first substrate on the anvil;using the vacuum source to apply vacuum pressure to the elastic filmwhile on the anvil to hold the activated elastic material in anelongated position; advancing the second substrate to position the firstsurface of the second substrate in contact with the activated elasticfilm and the second surface of the first substrate on the anvil; andultrasonically bonding the first substrate together with the secondsubstrate with the elongated activated elastic film positioned betweenthe first substrate and the second substrate.
 19. The method of claim 18wherein the activated elastic film comprises a first edge region and asecond edge region, and wherein the step of using a vacuum source toapply vacuum pressure to the elastic material comprises holding thefirst and/or second edge region in position, such such that said firstand/or second edge region remains unstretched.
 20. The method of claim11 wherein the activated elastic film comprises a skin having aplurality of tears.